Automated system for selecting packages from a storage area

ABSTRACT

A system for filling orders, such as prescriptions for patients, comprising a device for holding packages. Each package has the same type of contents being held in a predetermined location by the holding device. Each package has an identity which defines the contents therein. The holding device has a plurality of predetermined locations corresponding to a plurality of different types of contents. Additionally, the system is comprised of a device for supplying packages to the holding device. Also, there is a device for picking a package from the holding device that is identified in the order for the purpose of restocking the holding device. The picking device is in communication with the holding device and supplying device. In a preferred embodiment, the contents of each package is a single dosage of medicine.

RELATED APPLICATION

This is a continuation of Ser. No. 07/87/832 filed Apr. 21, 1992, nowabandoned which is a continuation-in-part of our U.S. patent applicationSer. No. 07/469,217 filed Jan. 24, 1990, now abandoned.

FIELD OF THE INVENTION

The present invention relates to an automated system for selectingstored articles. More specifically, the present invention relates to anautomated system for filling prescriptions and restocking medicines in apharmacy.

BACKGROUND OF THE INVENTION

Many industries store products or parts in a storeroom or storage areaand repeatedly select some of the stored items to fill orders or forother uses. Such items may range from small electronic components usedby a manufacturer of electronic devices to automotive parts, which varyin size, used by service departments of automobile dealerships. Usuallyone or more people are employed to retrieve the requested items and torestock new and returned items. These individuals may also be requiredto confirm that the requested items are compatible with one another andwith previously supplied items. If the supplied items are to be billedto a customer or charged to particular internal accounts, the list ofitems is first written by the requestor, and rewritten or entered into acomputer database by the storeroom attendant to create an invoice,supply list or other document. In some instances, further generations ofthe list are made by installers, users or billing clerks. Such methodshave built-in opportunities for mistakes every time a list is rewrittenand are less efficient than automated systems. Moreover, as labor costsrise and the size of inventory needed to be stored expands, theconventional storeroom and parts department become more and moreexpensive.

Some businesses have attempted to control costs by limiting inventorythrough standardization of parts. But such limits are not possible ordesirable in some industries, particularly in a hospital pharmacy.

Currently, in large hospital environments, doctors visit patients innursing units and write out medication orders for each patient. Apatient is typically placed on a certain medication which may requiremultiple doses of medication be administered over a period of a day.Some medications are administered at certain times of the day andpossibly at intervals of several hours. Patients may also requestcertain medications on an elective basis for disorders such asheadaches. These requests are included in the doctor's order that issent from the nursing unit to the central pharmacy of the hospital.

Once an order is received by the pharmacy, it is checked by registeredpharmacists and input into the pharmacy information system. These ordersreflect not only orders that are added to a particular patient'streatment, but changes in the medication treatment. The pharmacyinformation system combines this information with the patient's existingmedication schedule and develops a patient medication profile. A filllist is generated from that profile. The fill list is a list of all themedications that must be distributed to all patients for the day. Thisinformation is sent to the pharmacy printer where a hard copy isgenerated. Frequently, that hard copy or a copy thereof is sent to thebilling department so that the medication can be charged to the patientor his insurer.

At this point, the drugs for a particular patient are hand-picked byeither a pharmacist or a pharmacy technician and placed in theparticular patient's designated box. A registered pharmacist must thencheck the accuracy of the patient order before it leaves the pharmacy.Individual patient boxes are then loaded into a large cassette anddelivered to the nursing unit.

Approximately 30% of the drugs dispensed each day are returned to thepharmacy unused. Since each drug is individually packaged, the drugsmust be returned to the pharmacy stock. Patients are then credited forunused medication. This return and crediting process is a verytime-consuming task and requires significant amount of pharmacymanpower.

In a typical large pharmacy, up to 35 pharmacists and pharmacytechnicians are responsible for all aspects of the unit dose dispensingtask. Because this process is done manually, a certain amount of erroroccurs. Studies have estimated that a half-percent error rate is typicalin a large hospital. Since a hospital may dispense over 6,000 doses eachday, this error rate leads to a significant number of missed orincorrect doses.

Several companies have tried to automate this process through variousapproaches to the problem. Meditrol utilizes a vending machine approachto dispense the unit dose medications. Each nursing unit must have itsown stock of prescription drugs. Nurses key in a patient ID and thedrugs for that patient are then dispensed from the vending machine. Thissystem is very expensive because of the necessity of purchasing amachine for each nursing unit. Also, restocking each machine is a verytime-consuming task. Implementation of this system requires a completemodification of the current drug dispensing process which many hospitalsare reticent to undertake. The system claims no labor-saving advantagesfrom its implementation. This system is covered under U.S. Pat. No.3,917,045 titled "Drug Dispensing Apparatus" and dated Nov. 11, 1975.

Baxter Travenol offers a dispensing system from Samsung, a Koreancompany, which dispenses bulk solids into a package which is dispensedto the pharmacist. This system only dispenses the 200 most frequentlyused solids. A typical hospital pharmacy can contain over 1,500different medications, many in liquid, syringe or bottle form. Thesemedications cannot be automatically dispensed by this system, but mustbe manually selected by the pharmacist.

Neither system allows the dispensed medications to be automaticallyreturned to the storage area.

There is a need for an automated system which is able to dispense alldosage forms currently contained in a hospital pharmacy. Medicinesshould be automatically dispensed by the system per a patient order andplaced in individual patient medication boxes for a pharmacist to check.Each drug and each patient box should be individually bar coded so thatthe accuracy of the dispensing process can be automatically checked bythe system. Once drugs are returned to the pharmacy, the system shouldautomatically return each drug to its proper location in inventory andcredit the patient's account for the return. One system should also keepa running inventory and notify the user whenever inventory of aparticular item drops below a preset level and whether the shelf life ofan item has passed. With such a system, a hospital can recognizesignificant labor savings, as well as savings based on improved accuracyin the dispensing function and better tracking of inventory and expiredmedications.

SUMMARY OF THE INVENTION

We provide an automated method and apparatus for selecting andrestocking stored items, which is particularly useful for fillingpatient medication orders in a hospital pharmacy. The stored items mustbe packaged to be held in a storage rack. Preferably, each packagecontains a bar code corresponding to the package contents. The items arearranged in a main storage rack so that like items are in the samelocation and a predetermined location is provided for every item.

We prefer to provide a second rack or a designated portion of the mainstorage rack for receipt of new or returned items to be restocked. Suchitems can be randomly placed on this supply station for transmittal totheir respective predetermined locations on the storage rack.

We also provide a means for picking items from and placing items in thestorage rack and the supply station. The picking means preferably iscomprised of a gripper assembly mounted on a transport vehicle whichmoves along a track or other controlled route. The gripper assemblypreferably has a movable rod or other carrier for holding selecteditems, at least one vacuum head and associated controls for gripping andmoving selected items. We prefer to provide a bar code reader forreading item packages.

We also prefer to provide a conveyor on which boxes, patient medicationtrays or drawers can be placed. The conveyor is positioned so that thepicking means can place selected items into appropriate containers onthe conveyor.

We provide a processing unit with associated memory and data entryperipherals. This computer system receives the list of requested items,directs the picking means, checks the items selected and preparesreports. Data can be entered manually through a keyboard or bar codereader or electronically through an RS 232 port. Reports may be printed,displayed on a console or transmitted to a memory or another computerfor later use.

Other details and advantages of our method and apparatus will becomeapparent from the description of the preferred embodiments shown in thedrawings.

BRIEF DESCRIPTION OF THE DRAWINGS

In the accompanying drawings, the preferred embodiments of the inventionand preferred methods of practicing the invention are illustrated inwhich:

FIG. 1 is a schematic representation of our present preferred system.

FIG. 2 is a side view of a present preferred package.

FIG. 3 is a perspective view of one present preferred storage rack.

FIG. 4 is a perspective view of a portion of a second preferred storagerack.

FIG. 5 is a perspective view of a portion of a third preferred storagerack.

FIG. 6 is a schematic representation showing the storage rack, conveyorand movable support structure which holds a gripper assembly.

FIG. 7 is a schematic view of a present preferred gripper assembly.

FIG. 8 is a front view of a present preferred gripper assembly.

FIG. 9 is a side view of the gripper assembly of

FIG. 7 with the storing rod in a raised and extended position.

FIG. 10 is a side view of the gripper assembly of FIG. 8 with thestoring rod in a lowered and partially retracted position.

FIG. 11 is a diagram showing a preferred vacuum and pressure line forthe gripper assembly.

FIG. 12 is a schematic representation of the gripper assembly mounted ona vehicle.

FIG. 13 is a perspective view of a rod with packages thereon connectedto a support bar.

FIG. 14 is a schematic representation of a side view of a first rod anda second rod and having packages thereon attached to a portion of thesupport bar.

FIG. 15 is a schematic overhead view of an alternative system forfilling an order.

FIG. 16 is a flowchart of the filling process.

FIG. 17 is a flowchart of the check process.

FIG. 18 is a flowchart of the return process.

FIG. 19 is a flowchart of the restocking process.

DESCRIPTION OF THE PREFERRED EMBODIMENT

Referring now to the drawings wherein like reference numerals refer tosimilar or identical parts throughout the several views, and morespecifically to FIG. 1 thereof, there is shown a schematicrepresentation of a present preferred system 10 for filling orders, suchas prescriptions for patients. The system 10 contains storage racks 12for handling packages. We prefer to provide at least two storage racks12 and arrange them parallel to one another. Various storage rackdesigns can be used and certain present preferred storage racks areshown in FIGS. 3, 4 and 5. In our system, each package preferablycontains only one product, although the product may consist of two ormore related items, such as nut and bolt. When our system is installedin a hospital pharmacy, each package preferably contains a single doseof medicine.

A present preferred package 14 is illustrated in FIG. 2. Although thepackage could be a blister card or box, we prefer to use a clear plasticbag having a hole 15 to permit the package to be hung on a rod 30, 48,65 or 66 shown in FIGS. 3, 6 and 14. Each package preferably has a barcode 16 and a written description 17, which identify the contents of thepackage. A white area 17a can be created on the clear plastic bag overwhich the written description 17 can be printed, stamped or evenhandwritten. The bar code and the written description may include notonly the name of the product, but also its quantity, weight,instructions for use and expiration date. We also prefer to position thebar code and label on the package so that there is a large unmarked area62 through which one can see the contents of the package. FIG. 2represents a clear plastic bag for a unit dose of medicine. We can use abag having a perforation line for easy opening or a recloseable baghaving an interlocking rib type seal. The perforation line or rib sealis located along line 13. This type of bag is useful in a hospitalpharmacy which buys medicines in large or bulk quantities and mustrepackage the drugs in individual dose packages. Packages 14 can be anydesired size. We have used a rectangular package having dimensionsindicated by arrows A, B, C and D, wherein A is 3.5 inches, B is 1.0inch, C is 3.0 inches and D is 0.1875 inches. Alternatively, the package14 can have A equal 5.0 inches, B equal 1.25 inches, C equal 5.0 inchesand D equal 0.1875 inches.

An individual dose of medicine can be manually fed into an automatedpackaging system 98, as shown in FIG. 1, which automatically seals thepackage and prints a bar code and typewritten label directly on thepackage. In a preferred embodiment, we utilize the H-100™ packagingsystem as manufactured by Automated packaging Systems of Twinsburg,Ohio. With the addition of the Accu-print™ 100 programmable In-LineDirect Transfer Imprinter, also manufactured by Automated packagingSystems, a bar code can be printed directly on the medicine package.

A storage rack 12, which may also be used for a supply station, is shownin FIG. 3. This rack is configured to hold packages of the typeillustrated in FIG. 2. The rack has a rectangular frame 28, having anopen front and back. Running across the back are a plurality of back rodsupports 32 from which the rods 30 extend. The frame 28 with rodsupports 32 forms an X, Y coordinate system with each rod 30 andmedicine packages 14 therein having a unique X, Y coordinate. Packagesare placed in the storage rack so that each product is located at aknown X, Y coordinate. Since every product is in a known X, Y location,it is possible to direct an automatic picking means to any productlocation to select a desired item. The packages are segregated withinthe storage rack so that all packages in any given location have thesame contents.

Although we prefer to use racks in which packages are hung on rods,other types of racks can be used for storage racks and supply stationsin our system. In FIG. 4, we show the upper portion of a rack having arectangular frame 21 with an open front and closed back 23. Attached tothe back 23 are sets of brackets 25 positioned to hold packages 27. Tobe held securely in this rack, such packages must be fairly rigid.Blister cards and boxes can be used. If desired, a hole 15 could beprovided in the packages to permit them to be carried on a rod.

A top portion of another suitable rack having a rectangular frame 21,open front and closed back 23 is shown in FIG. 5. This rack has a set ofshelves 29, which may be inclined toward back 23. A set of dividers 31separates groups of packages 27.

The racks of FIGS. 3, 4 and 5 have two important common features. First,the packages are held in locations having known X, Y coordinates. Thosecoordinates could be single X, Y values as may correspond to theposition of the package holes 15 or a group of X, Y values defining anentire package. Second, there is sufficient clearance between packagesto allow automated picking means to select, grab and replace individualpackages.

Referring now to FIGS. 1 and 6, we provide storage racks 12 on eitherside of a track 42 over which a vehicle 44 may travel. The vehicle maybe column-shaped as in FIG. 6. Many types of drive systems could be usedto propel the vehicle. For example, one could provide a motor indicatedby block 47 to propel wheels (not shown) at the base of the vehicle.Alternatively, one may use a chain or cable running through the track 42to pull the vehicle to any desired location. Whatever drive system isused should be capable of moving the vehicle to positions along thetrack which correspond to the X coordinates of the packages within therack. Thus, computer 24, which controls the drive system, can direct thevehicle 44 to a location in front of the package or packages to beselected.

Packages are selected by a picking means 38, preferably of the typeillustrated in FIGS. 7 though 10. The picking means is mounted oncolumn-shaped vehicle 44 in a manner to allow controlled verticalmovement along that column. In this manner, the picking means 38 can bepositioned at locations along column 44 which correspond to the Ycoordinates of packages to be selected. The picking means 38 iscontrolled by a computer 24, or local area network of computers, havinga database. The database has the order to be filled and a record of thepredetermined locations 18 of each different product in the storage rack12. The computer 24 guides the picking means 38 based on informationcontained in the database, such that the picking means 38 picks apackage 14 according to the order to be filled. The picking means 38 canalso include means, such as a bar code reader 26 as shown in FIG. 7, fordetermining the identity 16 of a package 14 in the storage rack 12 or ina supply rack 20 and providing its identity 16 to the computer 24. Thecomputer 24 guides the picking means 38 to select the desired packagesand deliver them to a desired location. In the system of FIGS. 1 and 6,the packages are delivered to containers 36 located on conveyor 34. Whenthe system is installed in a hospital pharmacy, the containers 36 areindividual patient boxes in which the patient's medication is deliveredfrom the pharmacy to the appropriate floor or nurses' station. Thepatient boxes preferably are bar coded with a patient identificationcode. After a patient's prescription is filled and the patient box 36has all the medicine packages called for in the prescription, a conveyorbelt 34 moves the patient box 36 to a check station 80. An operator usesthe check station bar code reader 82 to scan the bar code label on thefilled patient box 36, see FIG. 15. The patient identification number istaken from the inputted bar code and the prescription of the patient isdisplayed on the check station screen 84 of the check station console 86connected to the computer or network of computers 24. The operator thenscans individual medicine package bar codes in the patient box 36. Theidentity of the medicine packages 14 in the patient box 36 isautomatically checked for correctness with respect to the patient liston the station screen 84. If the medicine packages 14 in the box 36 arecorrect, then the patient box is allowed to continue on towards theultimate destination and the next filled patient box 36 is then checked.If the medicine packages 14 in the patient box 36 are not correct, thenit is determined whether the error, whatever that may be, can becorrected. If the correction can be made, then the record on the checkstation screen 84 is corrected and the procedure for verifyingcorrectness is then repeated. If the problem cannot be corrected, thenthe patient box 36 can be manually filled or resubmitted to be filledwith missing doses by the system and the computer is notified that thepatient's prescription has not yet been filled.

In the event that a patient does not take all of the medicine which hasbeen prescribed, unused medicine is returned to the hospital pharmacy inthe patient box 36. Typically, patient boxes are transferred in acarrier which contains several patient boxes. This carrier is receivedat a return station 92. The patient box 36 is first removed from thecarrier returned from a nursing unit. An operator uses the returnstation bar code scanner 91 to scan the bar code on the patient box 36.The nursing unit number and the patient identification number is thenparsed from the inputted bar code of the patient box 36. The database isthen accessed and the patient dispensing record is retrieved. On thereturn screen 94, there is displayed for a particular patient at theoperator console 96, a list of the medicines ordered and dispensed tothe patient. The operator of the return station 92 then scans theidentity 16 of the medicine in the patient's box 36 with the returnstation bar code scanner 91. The medicine packages 14 that are foundthereon are verified as being dispensed to the patients. The expirationdate of the medicine in the medicine package 14 is then determined. Ifthe expiration date of a medicine in the medicine package 14 has passed,then the medicine package is discarded. If the expiration date has notpassed, then the returned medicine package 14 is placed in the supplyrack 20. If there is more medicine to be returned, the process is thenrepeated. If there is no more medicine in the patient box 36 to return,then the return station console 96 is checked to verify the correctnessof the medicine returned. If the screen is correct, then the returnrecord is accepted and the database is updated. If the screen 94 isincorrect, then the screen is corrected to correspond to the returnedmedicine packages 14 and the patient box 36. In this manner, the systemwill have developed a record of all medication given to each patient.That record can be transferred to a hospital billing system and used forbilling purposes. The data can also be input into an inventorymonitoring system and used to generate reports or orders for newsupplies.

We prefer to provide supply racks 20 which serve as a holding area forreturned and new products. These racks are comparable to storage racks12 and are accessed by the picking means 38 in the same manner. However,products are randomly placed in the supply racks either manually or bythe picking means. The supply racks 20 are shown in FIG. 1 at a positionwhere they are accessible to the picking means. However, we prefer thatthe supply rack be movable. Then it could be moved to other convenientlocations, such as near packaging system 98 for refilling.

When packages 14 are to be restocked onto the storage racks 12, thesupply rack 20 is placed in a predetermined position alongside thestorage racks 12. By being placed in a predetermined position, the X andY coordinates at which packages may have been placed in return racks 20are known to the computer 24. Picking means 38 is then positioned for agiven package in the return rack. The bar code reader 26 on the end ofpicking means 38 then scans the identity 16 of the package 14 that isabout to be picked. The process of picking the returned packages 14 isthe same as occurs with respect to the process of obtaining packages 14from the storage rack 12. The only difference is that the order of thepackages 14 and their identity as they are picked is saved in thecomputer 24. When the picking means is then moved to the storage racks12 the computer knows the identity of the respective medicine package 14on the picking means 38, which is about to be placed back onto thestorage racks 12.

The picking means 38 includes at least one gripper assembly illustratedin FIGS. 7 through 12. As shown in FIG. 12, we prefer to provide asupport bracket 41 extending from column 44. This bracket can move alongcolumn 44 in a vertical direction. A third actuator 43 is attached tobracket 41. Mounting 39 permits movement along rod 41 and movement atbar 43 in a direction normal to rod 41. A picking means 38, whichpreferably is the gripper assembly of FIGS. 7 through 10, is mounted toactuator 43 through actuator 45, which permits a 180-degree rotation ofthe gripper assembly. Actuator 43 permits horizontal movement of pickingmeans 38 in the Z direction.

The gripper assembly is preferably comprised of a housing 49, as shownin FIG. 7 having means for storing medicine packages 14, such as astoring rod 48. Assembly 38 also contains means 50 for obtaining apackage 14. The obtaining means 50 is slidingly attached to the housing49 such that it can move in a Z direction, which is perpendicular to theX, Y directions, to pick a package 14 from a support rod 30 in thestorage rack 12 or supply rack 20. Identifying means, for example, thebar code reader 26 shown in FIG. 8, is mounted on housing 49 such thatit can identify a package 14 to be picked by the obtaining means 50. Theobtaining means 50 preferably includes means for producing a suction,such as a vacuum generator 58 controlled by a vacuum sensor 58a whichdraws a vaccum through vacuum line 55 and vacuum valve 54. The obtainingmeans 50 also preferably includes an extension rod 52 in fluidiccommunication with a pneumatic in/out cylinder 53 and associated valve59, as shown in FIGS. 8 and 11. The extension rod 52 is slidinglyattached with respect to the Y and Z directions to the housing 49. Asuction is maintained through the vacuum lines 55 when the vacuum valve54 is activated to supply air to vacuum generator 48. The obtainingmeans 50 also can include a suction head 56 connected to the extensionrod 52 through which a package is picked with suction. The vacuum sensor58a will sense when a package is properly positioned on the suction head56, for example, by detecting air flow therethrough. The suction head 56and carried package are then moved to the storing means, such as thestoring rod 48, to deposit the package thereon. Preferably, the storingmeans is a storing rod 48 which extends from the housing 49 such thatthe suction head 56 and the extension rod 52 can deposit a package 14thereon. The obtaining means 49 is also composed of a cylinder 48A whichallows an assembly of both holding rod 48 and pusher plate 57 to move inthe Y direction. The holding rod 48 is also attached to a cylinder 48Bwhich allows the storage rod to retract and extend in reference to theobtaining means. The pusher plate 57B is also attached to a cylinder 57Awhich allows the plate to move in the positive Z direction. This actionis necessary to push drugs off of the storage bar 48 during the dumpprocess.

The extension rod 52 can move in the Y and Z directions to place apicked package on the storing rod 48 under the action of up/downcylinder 51 and in/out cylinder 53. Valve 57 activates cylinder 51 tomove both the cylinder 53 and the extension rod 52 in the Y direction.Valve 59 activates cylinder 53 to move the extension rod in the Zdirection. Valve 54 provides air to the vacuum generator 58 to suctionin head 56 sufficient to pick a package from a rod 30 of the supportstructure 28 and then hold it to the suction head 56. The suction head56 preferably has two faces 60 and 61 through which suction can bedrawn. One face 60 is capable of picking a package from a rod 30 of thestorage rack and the other face 61 is capable of picking a package froma storing rod 48 of the picking means 38. As shown in FIG. 2, eachpackage preferably has a face 62. The packages are held by the storingrod 48 and the rods 30 of the support structure 38 such that the face 62of each package is parallel to the Y axis. The outside face 60 isutilized when a package 14 is being removed from a rod 30 in the supplyrack, and the inside face 61 is utilized when a package is being removedfrom the storing rod 48 of the picking means 38.

In an alternative embodiment, the rods 30 extend from the double rodsupport bar 64 in sets of two as shown in FIG. 14. A first rod 65 and asecond rod 66 of each set point essentially in the Z direction, butapproximately 180 degrees apart from each other. This embodiment shownin FIG. 15 includes a first tooling support structure 70, a secondtooling support structure 72, a first end of arm tooling 67 and a secondend of arm tooling 68 that picks the packages 14. Each tooling supportstructure has at least one column type vehicle 44 and at least one track42 to support the column 44. Column 44 moves along the respective tracks42 to pick a given package 14 from a corresponding support rod 30, orrestock a support rod 30 with an associated package 14.

In the operation of the preferred embodiment in a hospital, doctorsvisit patients in nursing units and write out medication orders for eachpatient. A patient is typically placed on a certain medication treatmentwhich requires multiple doses of medication over a period of a day. Somemedications are administrated at certain times of the day and possiblyat intervals of several hours. Patients may also request certainmedications on an elective basis for disorders such as headaches. Theserequests are included in the doctor's order that is sent from thenursing unit to the central pharmacy of the hospital. Once an order isreceived by the pharmacy, it is checked by registered pharmacists andinput into the pharmacy information system. These orders reflect notonly orders that are added to a particular patient's treatment, butchanges in the medication treatment. The pharmacy information systemcombines this information with the patient's existing medicationschedule and develops a patient medication profile. A fill list isgenerated from that profile. The fill list is a list of all themedications that must be distributed to all patients for the day. Thisinformation is sent to the pharmacy printer where a hard copy isgenerated.

Means for communication between the pharmacy information system and thepresent system exist by either tapping the serial data print stream ofthe pharmacy information system or by a direct bi-directionalcommunication link. The relevant information concerning the patientincluding drug type, dosage and frequency is placed in the database ofthe system. The database contains information about which drugs are tobe dispensed that day to the patient and all drugs that have beendispensed in the past to the patient. Information from the pharmacyinformation system is received on an ongoing basis throughout the day.New information can be entered into the database at any time. Inaddition to the fill list, new orders and patient admittance, dischargeand transfer information are received and stored.

FIG. 16 is a flowchart with respect to the processing of a patientprescription. A similar method would be followed for retrieving otherstored products. The software for processing an order is started asindicated by box 180. Then the steps indicated by boxes 181 thru 202 arefollowed. Before a box is loaded onto the conveyers, the operator scansthe location barcode and the patient barcode on the patient box. Thesystem then checks its database to ensure that that patient is still atthat location. If a new patient has been transferred or admitted to thatlocation, the system automatically generates a barcode label with thatpatient's identification number on it. This label is then manuallyapplied to the patient box and the box is placed on the conveyor. If nopatient is registered in the room, the box is placed aside and theoperator proceeds with the next patient box to be filled. When the turncomes for the patient box 36 to be filled, it is shuttled into aposition on the conveyor 34 such that the gripper assembly 38 cancommunicate with the box 36 as shown in FIG. 1. A stationary bar codereader 90 reads the bar code on the patient box 36. The patientidentification number is then parsed from the bar code input. Thiscauses the fill list for that particular patient to be retrieved fromthe database as indicated in box 185. The fill list is converted to dataconsisting of locations and number of picks. At box 187 the data is thendownloaded to a robot controller or gantry control program in order forthe computer 24 to control the end of arm tooling 38 such that it knowswhat packages 14 to obtain and place in the patient box 36.

The system is now ready to pick the drugs 188. First, the column-typevehicle 44 goes to the rack where the drug to be selected is stored andstops at the X coordinate of that drug package. The picking means 38then moves along the column 44 to the Y coordinate of the medicinepackage to be picked. It is also turned to the proper storage rack 12which has the desired package 14. These actions may also be performedsimultaneously by the system 189.

When the end of gripper assembly 38 is properly positioned, the bar codereader 26 reads 190 the identity 16 on the medicine package 14 in orderto confirm that it is the proper medicine package to be picked withrespect to the patient's prescription. After such confirmation thesuction rod 52 extends in the Z direction by pneumatic cylinder 53 suchthat the outside suction face 60 contacts the package face 62. Valve 54activates a suction through the air lines 55 such that a suction drawnthrough the suction face 60 grabs the medicine package 14 sensor 58adetects when the contact is proper between the suction face 60 and themedicine package 14, as indicated at box 192 of FIG. 16. Then theextension rod 52 retracts from the rod 30 of the support structure 28,pulling the medicine package 14 with it. Once the medicine package 14 isclear of the rod 30, the extension rod 52 positions the medicine package14 that it has obtained, upon the storing rod 48 as indicated by box193.

The system now prepares for the next pick. This operation is indicatedby box 194 includes several actions. Once the package 14 is on thestorage rod 48, the vacuum valve 54 terminates the suction and themedicine package is released from the suction face 60. The vacuum valve57 then activates the cylinder 51 such that the extension rod 52 (andcylinder 53) are moved in the Y direction so the bottom of the suctionhead 56 is above the package 14 on the storing rod 48. The extension rodis then moved forward in the Z direction and downward in the Y directionby the respective valves and cylinders to clear the package and positionthe suction head 56 for the next pick. In an alternative embodiment thestorage rod 48 is moved down rather than moving suction head up 56 toprovide clearance between them when the suction head moves in a Zdirection. The computer 24 then notes that the medicine package 14 withthe appropriate medicine has been picked.

The final series of operations indicated by boxes 195 thru 202 involvesa comparison of the drug identified by the reader as having been pickedwith the list of drugs to be selected. If an incorrect drug was selectedthe gripper assembly moves to a reject area, places the incorrect drugthere, removes that drug from the list of items selected and is ready topick more drugs. If the correct drug was selected the system recordsthat fact and is ready to pick more drugs. The process is repeated forall the medicine identified in the patient's prescription until all ofthe medicine packages 14 needed have been picked.

The gripper assembly containing all desired packages then positionsitself so that it is over the patient box 36. The gripper assembly 38then positions the outside suction face 60 behind the medicine packageson the storing rod 48 that have been collected. Packages can be droppedinto the patient box by retracting rod 48 by actuating cylinder 48A tothe position shown in FIG. 10. The storage rod 48 is then moved into thenegative Z direction so that the suction face no longer holds thepackages in place. The cylinder 48B then causes the storage rod 48 to beretracted which will cause the drugs to be dumped into the box.

Alternatively, the suction head may be stroked forward in the Zdirection so that all packages 14 are pushed off the storing rod 48 intothe patient box 36. Movement of the suction head is accomplished by thevacuum system. Vacuum valve 57 activates the cylinder 51 to retract inthe positive Y direction such that the bottom of the suction head 56 isabove the tops of the packages 14 on the storing rod 28. Then vacuumvalve 59 activates cylinder 53 to retract the extension rod 52 in thenegative Z direction such that the outer suction face 60 is behind allof the medicine packages 14 on the storing rod 48. Vacuum valve 57 isthen activated such that the suction head 56 is dropped back down in thenegative Y direction to be behind the packages 14. Finally, vacuum valve59 is activated such that the extension rod 52 is extended in thepositive Z direction and the front suction face 60 pushes all packages14 off the storing rod 48 into the patient box 36.

In the event that the wrong medicine package 14 was scanned and ispicked, or the medicine has expired, then picking means 38 will haveplaced those packages in a reject or return area, where the medicinepackage 14 can be disposed. A pharmacy technician will then manuallysort the drugs in the reject area, removing expired drugs and placingthe others in the supply rack in order that they might be returned totheir correct location in the system. The process is then repeated forthe next drug on the prescription list that has not yet been obtained.

The flow chart of FIG. 17 is the process of checking the selectedpackages which have been placed in a patient box. Such checking isperformed at the check station. The process begins by calling up thecheck program indicated by box 105. The bar code on the patient box isscanned 106 and the patient number portion of the bar code is identified107. The patient number is displayed 108 on the screen at the checkstation. Then the packages in the patient box are scanned 109. Theidentification of the packages is compared with the list of drugs thathad been ordered for the patient in a verify step 110. If correctpackages are in the box, the checking of the box is complete and thesystem is ready for the next box 111. If the packages in the box do notmatch the order the system determines if the problem can be corrected112. If so, the correction is made 113 and the verify step is repeated.If not, the box is dumped 114 and the order is recorded as not filled orthe box is resubmitted and the missing medications are filled by thesystem. For example, should the system determine that an item is missingit may either create a modified list and send the box on with a modifiedlist or it may instruct the picking means to get the missing item.

The return process is shown in the flow chart of FIG. 18. The processstarts 115 by calling up the return program. The patient box containingthe returned items must be positioned so that the patient box can bescanned 116 for the patient identification number 117 and the nursingunit from which the box was returned. If the box has come from theproper nursing unit the system retrieves the patient dispensing record120 and displays that record 121 for the operator. Next the packages arescanned 122. The system preferably verifies 123 that the scannedpackages had been sent to the patient making the return. Next the systemchecks each package 124 to determine if the drug is useful or if it hasexpired, been recalled or otherwise should not be returned to the supplyrack. If no, the package is discarded 125. If yes, the package isreturned to the supply rack 126. If more drugs remain in the box theprocess is repeated 127. If no packages remain, the system may furtherprocess the list of returned packages 128 to modify the patient'srecord, update the system inventory log or display the list of returnsfor review by the operator.

The process of restocking returned or new packages to the storage rackis diagramed in FIG. 19. These packages are manually placed on a returnor supply rack and the program for restocking is called up 130. Theprogram causes the picking means to be positioned 131 so that thegripping assembly can pick packages from the return or supply rack. Thebar code on the first package is scanned 132 and the portion of thescanned bar code which identifies the drug is found 133. The system thenchecks the database 134 for the location in the storage rack which hasbeen designated for the identified product. The system extends thevacuum head 135 to engage the package. Suction is applied 136 and asuction sensor is checked. This should cause the package to be held bythe gripper assembly which fact will be confirmed by the sensor 137. Thegripper assembly positions the package 138 on the storage rod 48 in thegripper assembly. Then the suction is released and the gripper assemblyis ready to place additional packages on the storage rod. If morepackages remain on the return or supply rack 140, the process isrepeated until all packages are on the storage rod or the storage rod isfull. The gripper assembly is then moved to a position 141 in front ofthe storage rack to properly place the outermost package on the storagerod. That package is grasped 142 using back suction cups 61 (see FIG.11). The extension rod 52 is retracted in the negative Z direction suchthat the inside suction face 61 is in contact with the medicine package14. The sensing means 58 determines whether proper contact is made. Thenthe extension rod 52 is moved a predetermined distance in the positive Zdirection 143 to place the medicine package over a rod 30 of supportstructure 28. Vacuum valve 54 is then deactivated 144 to stop suction,allowing the medicine package 14 on the suction face 61 to drop awaytherefrom. The extension rod 52 then moves in the negative Z directiontowards the medicine packages 14 on the storing rod 48 to repeat theprocess. While it moves back to obtain another medicine package 14, thesensor 58 trips when contact is made. The process can be repeated 141until there are no more medicine packages 14 on the storing rod 48. Thecomputer 24 knows when to stop returning packages since it knew how manypackages had been placed on the storing rod 48.

In the event that all drugs to be returned or restocked at a particularstorage location are identical the process is some what different.Packages are picked from the supply rack in the method detailed above.The gripper assembly is then moved to a position in front of the storagerack to place the remaining packages on the storage rod. Cylinder 48Acauses the assembly of storing rod 48 and pusher plate 57B to move inthe negative Z direction. Storage rod 48 is co-linear with a rod 30 ofsupport structure 28. Pusher plate 57B then moves in the positive Zdirection pushing all remaining packages on storage rod 48 on to rod 30.

The restocking of the storage racks 12 can be carried out during theevening when packages are not being gathered to fill orders.Alternatively, restocking can be carried out simultaneously with pickingif the system 10 has a pair of rods as shown in FIG. 14, a first end ofarm tooling 67, second end of arm tooling 68 and a first toolingstructure 70 and a second tooling structure 72 is utilized, as shown inFIG. 15. While, for instance, the first end of arm tooling 67 is pickingmedicine packages 14 to fill a patient's prescription, the second end ofarm tooling 68 can be restocking the second side of the storage area 12.

Although the invention has been described in detail in the foregoingembodiments for the purpose of illustration, it is to be understood thatsuch detail is solely for that purpose and that variations can be madetherein by those skilled in the art without departing from the spiritand scope of the invention except as it may be described by thefollowing claims.

We claim:
 1. A system for selecting and delivering packages to fillorders comprising:a) a storage area comprised of a plurality of storagearea locations each location having package holding means sized andconfigured to hold a plurality of individual packages each individualpackage having a machine readable label which identifies a type ofpackage, the packages being held in a manner so that each package can beplaced into and removed from the storage area locations and so that themachine readable label on at least one package in a storage location canbe read without removing the package from the storage location, eachlocation having a distinct x, y coordinate; b) automated picking meanssized and configured to be able to hold packages, to select packagesfrom the storage area locations and place packages in the storage arealocations in accordance with computer controlled instructions, thepicking means having a gripper for grasping and moving the packages andhaving a picking means storage location sized and configured to hold aplurality of packages in a face to face relationship after the pluralityof packages have been retrieved from the storage area and prior todelivery of the plurality of packages to a desired destination separatefrom the picking means; c) means for moving the automated picking meansto selected storage locations; d) a computer having at least one memorywhich contains a program for directing the picking means to chosenstorage area locations and a database containing at least one x, ycoordinate location in the storage area for each package held within thestorage area the computer being connected to the automated picking meansand the means for moving the automated picking means; and e) a packagereader associated with the picking means and being positioned forreading the machine readable labels on packages located within thestorage area, wherein only one type of package is stored in each x, ycoordinate location.
 2. The system of claim 1 wherein the gripper is avacuum head.
 3. The system of claim 1 also comprising a sensor attachedto the picking means for determining when the package is grasped by thegripper.
 4. The system of claim 1 wherein the label is a bar code andthe reader is a bar code reader.
 5. The system of claim 1 wherein thelabel also contains an expiration date.
 6. The system of claim 1 whereinthe picking means contains a picking means storage area for holding theplurality of packages selected by the picking means.
 7. The system ofclaim 6 wherein the picking means storage area is comprised of at leastone storage rod and holes are provided in the packages to permit thepackages to be held on the storage rod.
 8. The system of claim 1 alsocomprising a supply station for receiving new and returned packages, thesupply station having a plurality of locations each location havingpackage holding means sized and configured to hold an least one packagein a manner so than the package can be placed into and removed from thelocations by the automated picking means, each location having adistinct x, y coordinate.
 9. The system of claim 8 also comprising meansfor moving the supply station wherein the supply station is removablypositioned adjacent the storage area.
 10. The system of claim 1 whereinthe package holding means in the storage area is comprised of aplurality of rods and a hole is provided in each package to permit thepackage to be held on the rods.
 11. The system of claim 1 alsocomprising at least one data transmission port attached to the computerthrough which a list of packages to be selected can be input and a listof packages selected by the system can be output.
 12. The system ofclaim 1 wherein the memory contains a program for checking comparabilityof products in packages selected by the picking means with otherproducts listed in the database.
 13. The system of claim 1 alsocomprising a conveyor positioned to receive packages from the pickingmeans.
 14. The system of claim 13 also comprising a plurality ofcontainers positioned on the conveyor, the containers being sized andpositioned to receive packages from the picking means.
 15. The system ofclaim 14 wherein the containers have machine readable labels.
 16. Thesystem of claim 15 wherein the labels are bar codes.
 17. The system ofclaim 14 wherein the labels are bar codes.
 18. The system of claim 14also comprising a check station located adjacent the conveyor, the checkstation having reading means for reading the machine readable labels.19. The system of claim 18 wherein the reading means is connected to thecomputer in a manner to input information from the machine readablelabels; the computer having a program for storing the input informationin the memory and for comparing the input information to otherinformation contained in the database.
 20. A system as described inclaim 18 wherein the picking means includes an least one gripper thatpicks the packages; and a tooling support structure having an least onecolumn to support the tooling and at least one row to support the columnsuch that the tooling means moves along the column as the column movesalong the row to pick a given package hanging from a correspondingsupport rod, said gripper able to turn at least 180° on the column topick packages Ion either the first or from selected storage locationswhich locations are positioned opposite and facing one another; andmeans for moving the column with respect to the row, said moving meanscontrolled by the computer and in communication therewith.
 21. Thesystem of claim 1 wherein the packages contain individual doses ofmedicine.
 22. The system of claim 1 also comprising a track over whichthe picking means travels according to directions supplied by thecomputer also comprising means for moving the picking means over thetrack.